TECHNICAL FIELD
The present invention relates to a safety and availability manifold system for a continuous process industry, in particular, petroleum downstream complexes and petro-chemical industry.
DEFINITIONS
- 3/2 solenoid valve is 3-port 2-position electro-mechanical valve used to control the flow of fluid through a conduit while being actuated with an external electric supply.
? Hot swapping is an operation to replace elements of a system without shutting down the entire system.
? Shuttle valve is a three-way valve with a floating ball at the center. With an input from one port, the ball shifts and blocks one of the other ports, thus allowing a fluid connection between the other two ports. With inputs from both the ports, the ball moves to the center, thus allowing the flow from the two ports to exit from the third port.
BACKGROUND
A key element that defines the safety for an industrial process is the ease with which the system can be fully or partially turned off in the face of eminent danger. System availability is defined as the degree to which a system stays operable under different operating conditions avoiding spurious trips. In processing and manufacturing industries valves play a critical role in controlling different operations. The arrangement of these valves defines the objective, whether the sequence satisfies the safety needs or the availability needs or both. To enforce safety, the valves are generally arranged in a series. If a single valve fails, the entire line is automatically defunct. To enforce availability, the valves are arranged in parallel. In this case when a single valve fails, the system continues to operate with the functioning of valves mounted in parallel.
Defined under operability, the valves are categorized as manual and automatic. One of the types of automatic valves is the 3/2 poppet valve also referred to as the 3/2 solenoid valve. The 3/2 poppet valve represents a 3-port 2-position poppet valve. The differentiating factor of the 3/2 valve from a regular 2/2 valve is the presence of an extra port for diversion of the fluid. Normally, fluid flows from an inlet port to an application port and otherwise an outlet port connected to an exhaust port.
One of the key problems associated with such systems is the current repair and restoration process under which there is an unavoidable requirement to shut the entire process in order to repair and restore valves. In a continuous process industry, this means a huge production loss for the whole of the time the valves being restored.
Hence, there is a requirement of a system, which would provide continuity of operations despite undergoing the process of repair and restoration.
OBJECTS
Some of the objects of the subject matter disclosed in the present disclosure aimed to ameliorate one or more problems of the state of the art or to at least provide a useful alternative are described herein below:
An object of the present disclosure is to provide a safety and availability manifold system that maintains system availability at all desirable time.
Another object of the present disclosure is to provide a safety and availability manifold system that provides for a platform for easy maintenance and repair of valves.
Yet another object of the present disclosure is to provide a safety and availability manifold system that provides for individual isolation of solenoid operating valves.
A further object of the present disclosure is to provide a safety and availability manifold system that provides for the required degree of availability and safety.
Still further object of the present disclosure is to provide a safety and availability manifold system that is reliable.
Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure provides a safety and availability manifold system for a petroleum downstream complexes and petro-chemical industry.
In accordance with an embodiment of the present disclosure, the manifold system having at least one intake and at least one exhaust comprises:
? at least two automatic valves coupled to one another so as to form series and parallel redundancies; and
? at least two manual operated valves corresponding to the two automatic valves that form series and parallel redundancies the manual operated valves being operatively coupled to an automatic valve in a hot swapping manner.
In accordance with the present disclosure, the manifold system further includes:
? at least one shuttle valve operatively coupled to the two automatic valves;
? an actuator with a rack and pinion arrangement connected to springs attached at opposite ends is operatively connected to the shuttle valve;
? one or more electrically-operated pressure sensors; and
? one or more indicators that are electrically coupled to the two automatic valves to indicate an availability status thereof.
Further, in accordance with the present disclosure, the automatic valve is a 3/2 poppet valve, whereas the manual operate valve is a 3/2 valve.
BRIEF DESCRIPTION OF DRAWINGS
A safety and availability manifold system of the present disclosure will now be described with the help of accompanying drawing, in which:
Figure 1 illustrates a circuit diagram of four solenoid valves in a de-energized condition, in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a circuit diagram of two solenoid valves in a de-energized condition, in accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION
A preferred embodiment of a safety and availability manifold system, hereinafter referred to as manifold system, of the present disclosure will now be described in detail with reference to the accompanying drawings. The preferred embodiment does not limit the scope and ambit of the disclosure. The description provided by way of example and illustration.
The embodiments herein and the carious features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The following description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the general concept, and, therefore, such adaptions and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
A key problem faced with current systems of safety and availability used in the manufacturing and processing industries is keeping the system online while conducting the repair and restoration work. The present disclosure describes a manifold system that keeps the entire system online while allowing the repair and restoration work to be carried out simultaneously.
Referring to the accompanying figures, Figure 1 illustrates a circuit of a manifold system 100 with four solenoid valves (SOVs) 102, 104, 106, and 108 in a de-energized condition, in accordance with an embodiment. A de-energized valve represents a failed valve and is subject to repair and replacement. In accordance with the present disclosure, the four solenoid valves (102, 104, 106, 108) are configured to stay ‘ON,’ which represents an energized state, during repair works. In an embodiment, an intake (shown by arrow) to the manifold system 100 is air, or neutral gas or liquid or natural gas. The four SOVs (102, 104, 106, 108) are arranged in a way that they form series as well as parallel redundancy. The concept of redundancy is that a single valve breakdown would not eliminate the normal operation of the circuit because the redundant valve would perform the required function and maintain the normal operation of the whole system.
Each SOV is attached with a 3/2 manually operated valve (MOV) in series. These MOVs are represented with the reference number 110 for MOV 1 in series with SOV 1 102, 112 for MOV 2 in series with SOV 2 104, 114 for MOV 3 in series with SOV 3 106 and 116 for MOV 4 in series with SOV 4 108. These four SOVs (102, 104, 106, 108) are categorized under three channels. According to one embodiment, the SOV 102 and SOV 108 are together categorized under Channel 1, SOV 104 is categorized under Channel 2 and SOV 106 is categorized under Channel 3. The manifold system 100 also uses indicators to depict a status of the SOVs. A total of four indicators A, B, C and D are used. In place of these indicators, electrically operated pressure sensors can also be used at these points. In an embodiment, the manifold system 100 can have either of these or both together.
The manifold system 100 further consists of 2 shuttle valves referenced with 118 for the first shuttle valve and 120 for the second shuttle valve. The second shuttle valve 120 is further connected with an actuator 122, which gets actuated on receipt of, for example, air. According to an embodiment, the actuator 122 is a rack and pinion arrangement with springs attached at opposite ends. The manifold system 100 further consists of an exhaust 124.
With the receipt of air into the actuator 122, the springs get compressed with the actuator 122 storing the air received, whereas with no air input, the springs flex and exhaust the stored air. The actuator 122 can be linear of rotary actuators used for operating process valves. The configuration of the circuit of the manifold system 100 as illustrated in the Figure 1 is such that the redundancy provided SOVs (102, 104, 106, 108) are subject to hot swapping with the help of the MOVs (110, 112, 114, 116).
The circuit of the manifold system 100 as illustrated in Figure 1 has three objectives. The first is to deliver the air to the actuator 122. In order to achieve this objective, 4 SOVs are provided, which based on their state are either energized or de-energized. The second objective is to deliver the residue to exhaust 124. The third objective is to enable hot swapping of the de-energized SOVs. All this is achieved by ensuring safety and availability in the system 100.
According to one embodiment, with all the SOVs (102, 104, 106, 108) in the de-energized state, the air is unable to traverse through the system 100, thereby not able to actuate the actuator 122. The exhaust air present in the system 100 is vented to the exhaust 124. According to another embodiment, where all the SOVs (102, 104, 106, 108) are energized, the air is able to traverse through the entire system 100, thereby actuating the actuator 122.
According to an embodiment, where one channel, say channel 2, is de-energized, and the remaining two channels 1 and 3 are energized, the air passes through the energized SOV 102, the first shuttle valve 118, the energized SOV 106, the second shuttle valve 120 and actuates the actuator 122. In this embodiment, the indicators A and C indicate availability, while indicators B and D indicate unavailability.
According to another embodiment, where SOV 102 is de-energized and the other SOVs 104, 106, and 108 are energized. The air passes through the energized SOV 104, the energized SOV 108, the first shuttle valve 118, the energized SOV 106, and the second shuttle valve 120 to actuate the actuator 122. In this case, the indicators, B, C and D indicate availability while the indicator A indicates unavailability.
According to yet another embodiment, where the SOV 108 is de-energized and the remaining three valves 102, 104, and 106 are energized, the air passes through the SOV 102, the SOV 104, the first shuttle valve 118, the SOV 106, and the second shuttle valve 120 to actuate the actuator 122. In this case, the indicators A, B, C indicate availability while D indicates unavailability.
According to a further embodiment, where the SOV 106 is de-energized while the remaining 3 channels are energized, the air passes through the energized SOV 102, the energized SOV 104, the first shuttle valve 118, the SOV 108 and the second ball valve 120 to actuate the actuator 122. In this case, the indicators A, B, D indicate availability and indicator C indicates unavailability.
In another case, where the SOV 102 and the SOV 106 are de-energized while the SOV 104 and the SOV 108 are energized, the air passes through the energized SOV 2 104, the energized SOV 4 108, and the second shuttle valve 120 to actuate the actuator 122. In this case, the indicators A and D indicate availability and indicators B and C indicate unavailability.
According to a still further embodiment, where the SOV 104 and the SOV 108 are de-energized while SOV 102 and SOV 106 are energized, the air passes through the energized SOV 102, the energized SOV 3 106, the first shuttle valve 118, and the second shuttle valve 120 to actuate the actuator 122. In this case, the indicators B and C indicate availability and indicators A and D indicate unavailability.
In a still further embodiment, where the SOV 102 and the SOV 108 are de-energized while the SOV 104 and the SOV 106 are energized, the air passes through the SOV 104, the first shuttle valve 118, the SOV 106 and the second ball valve 120 to actuate the actuator 122. In this case, the indicators B and D indicate availability and indicators A and C indicate unavailability.
In an embodiment, wherein two channels, say channel 2 (SOV 104) and channel 3 (SOV 106), are de-energized while the other remaining channel 1 (SOV 102 and SOV 108) is energized, the air passes through the SOV 102, but because the first shuttle valve 118 does not allow the passage from the SOV 102 to the SOV 108, the air is unable to reach the actuator 122. In this embodiment, only indicator A indicates availability while the indicators B, C, D indicate unavailability.
In another case, wherein only SOV 106 is energized while the remaining three SOVs are de-energized, the air is unable to reach the actuator 122. Similar is the case wherein only the SOV 108 is energized while the remaining SOVs de-energized. Again, the air is not able to reach the actuator 122. Yet similar is the case wherein only SOV 102 is energized while the remaining three SOVs are de-energized, the air is again unable to reach the actuator 122.
In a further case, wherein the SOV 102 and the SOV 104 are energized while the SOV 106 and the SOV 108 are de-energized, the air is unable to reach the actuator 122. In this case, none of the indicators indicate availability. Similar is the case when the SOV 106 and the SOV 4 108 are energized while the SOV 102 and SOV 104 are de-energized, the air is not able to reach the actuator 122. In a further case, wherein only the SOV 104 is energized while the remaining SOVs are de-energized, the air is unable to reach the actuator 122.
In yet another case, where the SOV 102 is de-energized and the rest of the 3 SOVs are energized, the residue air at the intake for the SOV 102 finds no escape. Though the availability for the system 100 is three indicators out of the four, yet the system 100 continues to function. In such a state, the corresponding MOV 110 is activated to perform hot swapping. This isolates the air supply to the SOV 102, which now can be taken out for maintenance. This ensures no stoppage of the process and system continues to work with the other working valves.
Figure 2 illustrates another circuit of the manifold system 100 having two SOVs 202 and 204 in a de-energized condition, in accordance with an embodiment. Here, two MOVs 206 and 208 are provided corresponding to the two SOVs 202 and 204. The SOVs are connected to an actuator 212 via a shuttle valve 210. The manifold system 200 consists of an exhaust 214, as shown. Further, A and B represent indicators indicating availability or unavailability of the system 100.
Similar to Figure 1, the circuit shown in Figure 2 is also configured to stay ‘ON,’ which represents an energized state, during repair works. Also, an intake (shown by arrow) to the manifold system 100 is air, or neutral gas or liquid or natural gas. The two SOVs (202, 204) are arranged in a way that they too form series as well as parallel redundancy.
The configuration of the circuit of the manifold system 100 as illustrated in the Figure 2 is such that the redundancy provided SOVs (202, 204) are subject to hot swapping with the help of the MOVs (110, 112, 114, 116). The working of the circuit as shown in Figure 2 is similar to as described above with reference to the circuit of Figure 1.
TEHNICAL ADVANTAGES
The manifold system, in accordance with the present disclosure described herein above, has several technical advantages including but not limited to the realization of the following:
? The equipment that employs the present system remains operational even when there is a fault with one or more valves.
? Further, it provides an indication as to which of the valves is non-functional or requires repair/restoration.
? The system enables repair and restoration of the valves, while the equipment is operational.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising” will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and therefore, such adaptions or modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments described herein. ,CLAIMS:1. A manifold system (100) comprising:
? at least two automatic valves coupled to one another so as to form series and parallel redundancies; and
? at least two manual operated valves corresponding to the at least two automatic valves, wherein each of the manual operated valves is operatively coupled to an automatic valve in a hot swapping manner.
2. The manifold system as claimed in claim 1 further comprises at least one shuttle valve (118,120, 210) operatively coupled to said at least two automatic valves.
3. The manifold system as claimed in claim 1 further comprises an actuator (122, 212) operatively connected to said at least one shuttle valve.
4. The manifold system as claimed in claim 1 further comprises one or more indicators (A, B, C, D) electrically coupled to said at least two automatic valves to indicate an availability status thereof.
5. The manifold system as claimed in claim 1, wherein the automatic valve is a 3/2 poppet valve.
6. The manifold system as claimed in claim 1, wherein the manual operate valve is a 3/2 valve.
7. The manifold system as claimed in claim 1 further comprises at least one intake and at least one exhaust (124, 214).
8. The manifold system as claimed in claim 3, wherein the actuator includes a rack and pinion arrangement connected to springs attached at opposite ends.
9. The manifold system as claimed in claim 1, wherein an intake to the manifold system comprises at least one of air, neutral gas, liquid and natural gas.
10. The manifold system as claimed in claim 1 further comprises electrically-operated pressure sensors.